Work Procedure, Changing Brake Fluid

Special tools, testers and auxiliary items required

Fig 1: Brake Pedal Depressor V.A.G 1869/2

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Brake pedal depressor V.A.G 1869/2

Fig 2: Brake Filler And Bleeder Unit VAS 5234

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Brake filling and bleeding tool VAS 5234

Vehicles → 1999 (→ X)

Observe operating instructions for brake charger/bleeder unit VAS 5234 !

Fig 3: Brake Fluid Reservoir

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Remove cap from brake fluid reservoir - 1 -.

Fig 4: Extracting Brake Fluid From Reservoir

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Extract as much brake fluid as possible from brake fluid reservoir using suction hose of brake charger/bleeder unit VAS 5234 - 1 -.
Alternatively, extract as much brake fluid as possible using a suction bottle with built-in strainer.

NOTE:

After extracting, observe that no further brake fluid runs into the reservoir (the brake fluid level in the reservoir must align with the lower edge of the strainer).

Vehicles 2000 → (Y →)

Observe operating instructions for brake charger/bleeder unit VAS 5234 !

Fig 5: Brake Fluid Reservoir

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Remove cap from brake fluid reservoir - 1 -.

Fig 6: Identifying Locking Bolt Of Brake Fluid Reservoir

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Remove locking bolt - arrow - of brake fluid reservoir.

Fig 7: Connect Suction Hose Of Brake Charger/Bleeder Unit VAS 5234 To Tube 1 Or 2 Of Brake Fluid Reservoir

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Connect suction hose of brake charger/bleeder unit VAS 5234 to tube - 1 - of brake fluid reservoir.
Extract as much brake fluid as possible from brake fluid reservoir using suction hose of brake charger/bleeder unit VAS 5234.
Disconnect suction hose.

Connect suction hose of brake charger/bleeder unit VAS 5234 to tube - 2 - of brake fluid reservoir.
Extract as much brake fluid as possible from brake fluid reservoir using suction hose of brake charger/bleeder unit VAS 5234.
Disconnect suction hose.
Screw locking bolt onto brake fluid reservoir.

Continued for all vehicles:

WARNING: Do not reuse, (used) extracted brake fluid.

Install brake pedal depressor V.A.G 1869/2 between drivers seat and brake pedal and apply tension.

Fig 8: Brake Charger/Bleeder Adapter Installed On Brake Fluid Reservoir

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Screw adapter - 1 - onto brake fluid reservoir.

Fig 9: Connecting Filler Hose To Brake Charger/Bleeder Adapter

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Connect filler hose - 1 - of brake charger/bleeder unit VAS 5234 to the adapter.

Vehicles with manual transmission:

Pull cover cap off clutch slave cylinder bleed screw.

Fig 10: Connecting Bleeder Hose To Clutch Slave Cylinder

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Connect bleeder hose - A - of collector bottle on bleeder screw of the clutch slave cylinder - arrow -, open the bleeder screw, and allow approx. 0.1 liters to flow out. Close bleeder screw and install cover cap.
Operate clutch pedal several times.

Continued for all vehicles:

Pull cover caps off bleeder screws of brake calipers.

Fig 11: Connecting Bleeder Hose (Rear Caliper)

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Connect bleeder hose - 1 - of collector bottle to a rear bleeder screw ^{* See footnote} , open bleeder screw and allow the corresponding brake fluid quantity to flow out (see table below). Close bleeder screw.

*Bleed right rear first.

Repeat work sequence on other side of vehicle at rear.

Fig 12: Connecting Bleeder Hose (Front Caliper)

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Connect bleeder hose - 1 - of collector bottle to a front bleeder screw ^{* See footnote} , open bleeder screw and allow the corresponding brake fluid quantity to flow out (see table below). Close bleeder screw.

* Bleed right front first.

Repeat work sequence on other side of vehicle at front.

Table - Sequence / quantity of brake fluid

Sequence: Brake caliper	Brake fluid quantity which must flow out of brake calipers:
	Vehicles → 1999 (→ X)	Vehicles 2000 (Y →)
Right rear	0.4 to 0.5 liter	0.2 liter
Left rear	0.4 to 0.5 liter	0.2 liter
Right front	0.4 to 0.5 liter	0.2 liter
Left front	0.4 to 0.5 liter	0.2 liter
Total amount ^{* See footnote}	2 liter	1 liter

* Including brake fluid extracted from brake fluid reservoir and quantity from clutch slave cylinder.

Fit cover caps to brake caliper bleed screws.
Move filler lever on brake charger/bleeder unit VAS 5234 to position - B - (see operating instructions).
Take filler hose off adapter.
Unscrew adapter from brake fluid reservoir.

Check brake fluid level and correct if necessary.

Fig 13: Brake Fluid Reservoir

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Screw in cap - 1 - of brake fluid reservoir.
Remove brake pedal depressor.
Check pedal pressure and brake pedal free play. Free play: Max. ¹ /₃ of pedal travel